Foldable case for use with an electronic device

ABSTRACT

This is directed to a case for securing and protecting an electronic device. The case can include a cover connected to a pouch by a hinge such that the cover can be overlaid over a device interface (e.g., a device display). The case can be constructed by layering and combining several types of materials, including for example materials having resistant outer surfaces, materials limiting the deformation of the case, materials providing a soft surface to be placed in contact with the device, and rigid materials for defining a structure of the case. In some embodiments, the case can include a tab that allows a user to fold open the cover of the case to form a triangular prism. The prism can be placed on any of its surfaces such that the device can be oriented towards a user at particular angles (e.g., a typing-specific orientation and a media playback orientation).

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application is a continuation of U.S. application Ser. No.14/167,600, filed Jan. 29, 2014, entitled “FOLDABLE CASE FOR USE WITH ANELECTRONIC DEVICE,” now U.S. Pat. No. 9,760,118 issued Sep. 12, 2017,which is a continuation of U.S. application Ser. No. 12/683,328 filedJan. 6, 2010, entitled “FOLDABLE CASE FOR USE WITH AN ELECTRONICDEVICE,” now U.S. Pat. No. 8,672,126 issued Mar. 18, 2014, the contentsof which are incorporated by reference herein in their entirety for allpurposes.

BACKGROUND

This is directed to a case for protecting an electronic device. Inparticular, this is directed to a case having a foldable flap forselectively covering a display of the device, and for creating a standsupporting the device in a particular orientation.

A portable electronic device can include several interfaces throughwhich a user can interact with the device. In particular, a device caninclude one or more displays and input interfaces via which the user canconsume displayed content or control the manner in which content isdisplayed. The device can include an outer shell supporting the severalinterfaces and defining a volume into which electronic device componentscan be placed and supported. For example, the outer shell can be used toretain a power supply (e.g., a battery), processing circuitry,communications circuitry, positioning circuitry, storage and memory, andelectrically conductive paths (e.g., a bus) connecting the devicecomponents.

The outer shell can be constructed from one or more distinct components.For example, the outer shell can include a housing having one or morecomponents, a bezel placed around the periphery of the housing, and adisplay. The housing can include a back plate and sidewalls extendingfrom the back plate that the bezel can engage. The bezel can include oneor more features for engaging and retaining the window within the bezelperiphery.

During use, the device outer shell can be exposed to impacts or to theenvironment around the device. Because impacts can damage the outershell or damage components within the device, a user may wish to protectan electronic device by placing the device in a protective case. Theprotective case can be constructed from any suitable soft or hardmaterial, and can protect some or all of the electronic device. Forexample, the case can cover the housing and bezel and only part of thedisplay. As another example, the case can substantially the entirety ofthe electronic device such that the device can be removed from the caseduring use. As still another example, the case can selectively cover thedisplay (e.g., with a cover). The cases, however, may have limitedaesthetic appeal or may have limitations in the manner in which theyprotect the device.

SUMMARY

This is directed to a case for use with a portable electronic devicehaving a display. In particular, this is directed to a case having apouch into which an electronic device can be placed, and a cover thatcan fold over the pouch to selectively protect the device display.

To protect an electronic device display, the case can include a pouchelement coupled to a cover element by a hinge. The pouch element canprovide a protective surface around at least some of the electronicdevice. For example, the pouch can protect one surface and the sidewallsof the device, leaving only the display window exposed. The hinge andcover can be sized such that the cover can be folded over the pouch tosubstantially entirely cover the exposed display window.

The case can be constructed from any suitable material. In someembodiments, the case can be constructed by combining several differentmaterials having different properties. For example, several differentmaterials can be layered to form the case. The materials can include,for example, polyester microfiber, polycarbonate fiber, polyurethaneadhesive, polyester knit, and polyurethane sheets. The differentmaterials can be layered in different orders, and can include only someof the materials based on the section of the case. For example, portionsof the cover can include fiberglass plates, but portions of the pouchcan include only softer layers (e.g., polyurethane and microfiber).

The case can include one or more tabs for holding the case at an anglerelative to the ground. For example, a back surface of the case caninclude a tab into which the cover can be folded. As the cover is foldedinto the tab, the case can define a triangular shape that can bedisposed on any of the three sides of the triangle. In some embodiments,the length of the sides of the triangle can be selected to providedifferent viewing angles for the device within the case (e.g., a typingangle and a media playback angle).

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features of the present invention, its nature andvarious advantages will be more apparent upon consideration of thefollowing detailed description, taken in conjunction with theaccompanying drawings in which:

FIG. 1 is a schematic view of an illustrative electronic device inaccordance with one embodiment of the invention;

FIGS. 2A-C are a series of schematic views of an illustrative case inaccordance with one embodiment of the invention;

FIGS. 3A-C are a series of schematic views of an illustrative case inaccordance with one embodiment of the invention;

FIG. 4 is a schematic view of an illustrative pouch used in a case forretaining an electronic device in accordance with one embodiment of theinvention;

FIG. 5 is an end view of the pouch of FIG. 4 taken from viewpoint 402 inaccordance with one embodiment of the invention;

FIG. 6 is a schematic view of the pouch of FIG. 4 in which the flap hasbeen folded over a device in accordance with one embodiment of theinvention;

FIG. 7 is an end view of the pouch of FIG. 6 taken from viewpoint 402 inaccordance with one embodiment of the invention;

FIG. 8 is a cross-sectional view of the flap of the pouch of FIG. 4along line 8-8 in accordance with one embodiment of the invention;

FIG. 9 is a cross-sectional view of periphery stack 420 taken along line9-9 in accordance with one embodiment of the invention;

FIG. 10 is a cross-sectional view of the tab and periphery stack of thepouch of FIG. 4 taken along line 10-10 in accordance with one embodimentof the invention;

FIG. 11 is a schematic view of a base stack in accordance with oneembodiment of the invention;

FIG. 12 is a cross-sectional view of base layer stack 1110 taken alongline 12-12 and connected to a peripheral layer stack in accordance withone embodiment of the invention;

FIGS. 13A and 13B are end views of a folded over case defining a prismin accordance with one embodiment of the invention;

FIG. 14 is a cross-sectional view of tab 1150 taken along line 14-14 inaccordance with one embodiment of the invention; and

FIG. 15 is a flowchart of an illustrative process for assembling a casefor protecting an electronic device in accordance with one embodiment ofthe invention.

DETAILED DESCRIPTION

An electronic device can include an external shell in which differentcomponents can be secured to provide electronic device functionality.The external shell can include one or more interfaces for interactingwith the device, including for example, one or more displays and inputmechanisms. As another example, the external shell can include one ormore ports or connectors, or openings for the ports or connectors (e.g.,USB, power and audio connectors). As still another example, the externalshell can include an opening for a speaker. To protect the externalshell from impacts or other external forces applied to the device, thedevice can be placed within a case.

The case can have any suitable shape suitable for protecting at least aportion of the electronic device. In some embodiments, the case caninclude a primary pouch for receiving the electronic device. The pouchcan include an opening through which one or more of a display and aninput interface can be accessible. In some embodiments, the opening caninclude a transparent film or layer through which the interface can beaccessed (e.g., an interface through which a touch interface can beoperated). To protect the display and interface through the opening, thecase can include a cover connected to the pouch by a hinge, such thatthe cover can be folded over the pouch opening.

The case can be constructed from any suitable material to provide aparticular aesthetic finish or desired level of protection. For example,the case can be constructed from a hard material. As another example,the case can be constructed from a softer material, but include one ormore hard elements to provide resistance to impacts. In oneimplementation, the case can be constructed by layering different typesof material to form a stack. The material stack can include differenttypes of materials, including materials selected based on differentphysical properties. For example, the material stack can include a softmaterial (e.g., to be placed in contact with the device, a hard material(e.g., fiberglass) to withstand impacts, and a stain-resistant orwater-resistant material (e.g., polyurethane) to provide a pleasingouter surface for the case.

The case can include a tab embedded or attached to the back surface ofthe pouch such that the cover can be folded back along the hinge andsecured with in the tab. This can define a triangular prism, where thecover, hinge and pouch of the case define the three rectangular sides ofthe prism. The tab can be positioned on the pouch such that the lengthof the hinge and the length of the cover provide two different angles atwhich the case can be positioned. For example, the angles can beselected to optimize a typing angle and a viewing angle for the device.

Any suitable electronic device can be placed within the case. FIG. 1 isa schematic view of an electronic device in accordance with oneembodiment of the invention. Electronic device 100 can include housing110, bezel 112, and window 120. Bezel 112 can be coupled to housing 110in a manner to secure window 120 to the bezel. Housing 110 and bezel 112can be constructed from any suitable material, including for exampleplastic, metal, or a composite material. In one implementation, housing110 can be constructed from plastic or aluminum, and bezel 112 can beconstructed from stainless steel. Window 120 can be constructed from anysuitable transparent or translucent material, including for exampleglass or plastic. Different electronic device components can be retainedwithin electronic device 100 to provide different functionality to theuser.

To protect the electronic device from damage caused by impacts or towear and tear caused by the environment, the electronic device can beplaced in a case. FIGS. 2A-C and FIGS. 3A-C are a series of schematicviews of an illustrative case in accordance with one embodiment of theinvention. Cases 200 and 300 can be operative to receive an electronicdevice, for example within pouch elements 210 and 310, respectively. Thepouch elements can include an opening through which a display can beviewed (e.g., described in more detail below). To protect the display,cases 200 and 300 can include covers 220 and 320, respectively,connected to the pouch elements via hinges 222 and 322, respectively.The hinges 222 and 322 can be constructed from a pliable material suchthat covers 220 and 320 can bend towards or away from the opening ofpouches 210 and 310 (e.g., over the display to protect the devicedisplay when stored, or behind the pouch exposing the display when thedevice is in use.

Cases 200 and 300 can include flap 215 assembled into or coupled to anopening in pouches 210 and 310, respectively into which the device canbe inserted. Flaps 215 and 315 can extend away from the openings suchthat the flaps can be folded over the device and retain the devicewithin the pouch. In some embodiments, flaps 215 and 315 can include oneor more rigid elements for assisting a user in folding the flap over thedevice, or for maintaining the flap between the device and the pouchsurface.

In some embodiments, a user may wish to fold covers 220 and 320 behindpouch elements 210 and 310, respectively, so as to define other surfaceson which the case may rest. For example, a user can fold covers 220 and320 into tabs 250 and 350, respectively, such that cases 200 and 300form prisms, where each of pouch elements 210 and 310, hinges 222 and322, and covers 220 and 320 define side walls of the prism. The coverscan be placed on any of the sidewalls of the prism (e.g., resting on thehinge or on the cover) such that the device display within the pouch isangled to the user at a particular angle. In some embodiments, theposition of tabs 250 and 350, and the length of hinges 222 and 322, andcovers 220 and 320 can be selected such that the device is displayed ata particular angle when cases 200 and 300 rest on hinges 222 and 322,and covers 220 and 320.

Cases 200 and 300 can be oriented in any suitable manner. In theexamples of FIGS. 2A-C and FIGS. 3A-C, cases 200 and 300 are oriented inlandscape and portrait modes, respectively. For example, hinge 222 isalong the long end of rectangular pouch element 210, while hinge 322 isalong the short end of rectangular pouch element 310. It will beunderstood, however, that the pouch element can have any suitable shape,and that the hinge can be along one or more of any of the sides of thepouch element (e.g., a hinge along two non-adjacent or non-continuousedges of a multi-sided polygon. For the sake of simplicity, however, thefollowing discussion will provide examples and details in the context ofthe landscape-oriented cases (e.g., case 200).

FIG. 4 is a schematic view of an illustrative pouch used in a case forretaining an electronic device in accordance with one embodiment of theinvention. Pouch element 400 can include a back layer or primary stack410 to which a periphery or secondary stack 420 can be coupled.Periphery stack 420 can be positioned around the periphery of back layerstack 410 such that when an electronic device is inserted within pouch400, the periphery of the device is constrained between stacks 410 and420. The width of periphery stack 420 can be selected based on anysuitable criteria, including for example the size of the device to beplaced within the pouch. In particular, periphery stack 420 can be sizedsuch that an electronic device cannot pass through an opening of theperiphery stack (e.g., opening 422, described below) once it has beeninserted in the pouch. Periphery stack 420 can include opening 422through which the electronic device can be visible and manipulated. Forexample, opening 422 can be substantially sized to match the size of adisplay area or window of the device. As another example, opening 422can be sized such that a display and an input interface (e.g., akeyboard) are visible and accessible through the opening.

An electronic device can be placed within pouch 400 (e.g., betweenstacks 410 and 420) using any suitable approach. In some embodiments,the pouch can include an opening through which the device can be slidinto the pouch. This may be necessary if opening 422 is sized such thatthe device cannot pass through the opening (e.g., for insertion orremoval). FIG. 5 is an end view of the pouch of FIG. 4 taken fromviewpoint 402 in accordance with one embodiment of the invention. Asshown in FIG. 5, pouch 400 can include opening 440 through which device500 can be inserted. To secure the electronic device between stacks 410and 420, flap 430 can be coupled with or embedded within one of thestacks (e.g., stack 420). Flap 430 can extend out of periphery stack 420and away from opening 422 such that flap 430 can be folded towards stack410 and define a sidewall between stacks 410 and 420. FIG. 6 is aschematic view of the pouch of FIG. 4 in which the flap has been foldedover a device in accordance with one embodiment of the invention. Asshown in FIG. 6, flap 430 has been folded within opening 440 and towardsstack 410 of pouch 400. FIG. 7 is an end view of the pouch of FIG. 6taken from viewpoint 402 in accordance with one embodiment of theinvention. As shown in FIG. 7, flap 450 can around device 500 such thatthe free end of flap 430 is between device 500 and stack 410. This canallow flap 430 to form a sidewall for pouch 400, and thus secure device500 on all sides (flap 430 on one side, and the interface between stacks410 and 420 on the other sides).

Returning, to FIG. 4, flap 430 can have any suitable width 432 adequatefor securing the electronic device once flap 430 has been folded beneaththe device. In particular, width 432 can be selected such that width 432is substantially larger than height 434 of device 500. The length ofwidth 432 less height 434 can be selected such that it providessufficient resistance (e.g., from friction between flap 430 and stack410 to prevent flap 430 from slipping out). To enhance a user's ease ininserting flap 430 around device 500, flap 430 can include one or morerigid elements 436 and 438, also referred to as a first element and asecond element, respectively, separated by flexible portion 437. In someembodiments, flexible portion 437 can be the same as the non-rigidportions of flap 430 (e.g., rigid elements 436 and 438 are created fromthe introduction of addition materials within flap 430). The width ofrigid element 436, as well as the position of rigid element 436 relativeto the border of flap 430 and stack 420 can be selected such that a usercan easily fold rigid element 436 over a device and into pouch 400. Inparticular, the width of rigid element 436 can be no more than thedistance 433 between rigid element 436 and stack 420 (e.g., the smallestdistance between portions of rigid element 436 and stack 420). In otherwords, flexible portion 437 can extend to distance 433.

Because the height of the device (e.g., height 434) is less thandistance 433 between rigid element 438 and stack 420, flap 430 caninclude an additional section that a user may wish to insert betweendevice 500 and stack 410 to ensure that device 500 remains securedwithin pouch 400 (e.g., so that only an amount of flap 430 equal toheight 434 is not between the device and the back layer stack). Rigidelement 438 can substantially be placed within this portion to provide ahard component that a user can easily slide into pouch 400. Rigidelement 438 can have any suitable size, including for example a width ofno more than the different between distance 433 and height 434 (e.g.,the length of the amount of flap 430 remaining to slide within pouch400). In some embodiments, rigid element 438 can be placed at the limitof height 434 to provide guidance as to how far flap 430 should beinserted.

Rigid elements 436 and 438 can be constructed from any suitablematerial. In some embodiments, rigid elements 436 and 438 can includepolycarbonate layers providing a that are flexible for bending around anaxis in the plane of the layers, but stiff and resisting bending aroundan axis that is not in the plane of the layers (e.g., perpendicular tothe plane of the layers). FIG. 8 is a cross-sectional view of the flapof the pouch of FIG. 4 along line 8-8 in accordance with one embodimentof the invention. The cross-section 800 of flap 430 can include severalmaterials. Layers 802 and 804 can form the outermost surfaces of flap430. Because at least one of layers 802 and 804 will be in contact withthe electronic device when it is in the pouch (e.g., layer 804), thematerial selected for these layers can be soft so as not to scratch thedevice shell. In one implementation, layer 802 and 804 can beconstructed from microfiber (e.g., polyester microfiber). Although theexample of FIG. 8 shows layers 802 and 804 being constructed from thesame material, different materials can instead be used. In oneimplementation, at least one of layers 802 and 804 (e.g., layer 802) canbe the extension of a layer of periphery stack 420 (e.g., a layer cominginto contact with the electronic device in other portions of pouch 400),and therefore also a soft layer.

Layers 802 and 804 can be coupled to each other using any suitableapproach, including for example using an adhesive. In the example ofFIG. 8, flap 430 can include adhesive layer 810 extending between layers802 and 804. Any suitable adhesive can be used, including for example apolyurethane based pressure adhesive. Flap 430 can include rigidelements 836 and 838, corresponding to rigid elements 436 and 438 (FIG.4). Rigid elements 836 and 838 can be constructed from any suitablematerial having sufficient stiffness or rigidity. In one implementation,rigid elements 836 and 838 can be constructed form a fiberglasscomponent (e.g., a fiberglass board). To ensure that rigid elements 836and 838 bond to layers 802 and 804, flap 430 can include additionaladhesive layers 812 and 814 applied to the surfaces of the rigidelements.

Returning to FIG. 4, pouch 400 defines an enclosure for the electronicdevice by binding base layer stack 410 to periphery stack 420. Peripherystack 420 can define a surface having opening 422 through which a usercan interact with device 500. Opening 422 can be empty, or alternativelycan be filled by a transparent or translucent component that retains theuser's ability to interact with the device. Periphery portion 424 ofperiphery stack 424 can define a substantially continuous surface forretaining the edges (e.g., the periphery) of device 500. Peripheryportion 424 can have any suitable width (e.g., width 425) adequate forretaining device 500. In particular, width 425 can be selected such thatdevice 500 cannot be removed from pouch 400 through opening 422, but notso large as to adversely affect a user's interaction with the deviceinterface. Although width 425 is shown to be constant in pouch 400, itwill be understood that in some embodiments, width 425 can vary.

When device 500 is inserted into pouch 400, the small width 425 ofperiphery stack 420 can cause the periphery portion to flare out, andadversely affect the cosmetic appeal and use of the case. To ensure thatperiphery stack 420 remains in contact with the device enclosure,periphery stack 420 can include rigid ring 426 within periphery portion424 and defining a continuous or substantially continuous ring aroundopening 422. Ring 426 can prevent periphery portion 424 from flaring out(e.g., stretching away from the device enclosure) and instead maintainthe surface of the device having the display in contact with the pouch.

Rigid ring 426 can be embedded within periphery stack 420 using anysuitable approach. FIG. 9 is a cross-sectional view of periphery stack420 taken along line 9-9 in accordance with one embodiment of theinvention. Cross-section 900 of periphery stack 420 can include severallayers having different physical properties combining to provide aparticular cosmetic and physical effect. On its outermost surface,periphery stack 420 can include external layer 902. Layer 902 caninclude any suitable property, including for example an aestheticallypleasing surface, a surface that is comfortable to the touch, resistantto stains, tears, or other damage, or has any other property. In oneimplementation, layer 902 can be constructed from polyurethane. Becausepolyurethane is stretchable, periphery stack 420 can include layer 904for resisting the deformation by stretching of layer 902. For example,layer 904 can include a polyester knit that resists to tension along theplane of the knit. Layer 904 can be bonded to layer 902 using anysuitable approach, including for example using an adhesive layer (notshown), but pressure, or any other suitable approach. In someembodiments, an adhesive layer on the other side of layer 904 (e.g.,adhesive layer 907) can traverse layer 804 (because it is knit) andensure that layer 904 bonds to layer 902.

To form the rigid ring around the periphery of periphery stack 420,cross-section 900 can include rigid layer 910. Rigid layer 910 can beconstructed from any suitable material, including for example fiberglass(e.g., as described above in connection with ring 426, FIG. 4). Toensure a proper bond between layer 910 and the remaining layers,adhesive layers 906, 907 and 908 can be applied around rigid layer 910(e.g., adhesive layers 907 and 908 on the top and bottom surfaces oflayer 910, and layer 906 between layers 904 and 912 where there is norigid layer 910). Layers 906, 907 and 908 can be formed using anysuitable adhesive, including for example a pressure or heat adhesive(e.g., a polyurethane based adhesive).

The last layer of periphery stack 420 is placed in contact withelectronic device enclosure. Accordingly, layer 912 can be constructedfrom a soft material that will not damage the enclosure. Such materialscan include, for example, a microfiber (e.g., polyester microfiber).Stack 420 can be assembled in any suitable manner. In some embodiments,each layer can be individually added and adhered or integrated in thestack in sequence. Alternatively, some or all of the layers can beoverlaid, and a pressure or heat-based process can be applied toassemble the stack. The individual layers can be pre-cut and assembled,or alternatively can be assembled and once the stack crated, cut to aparticular shape (e.g., die cut).

In some embodiments, flap 430 can include at least one layer that isshared with periphery stack 420. FIG. 10 is a cross-sectional view ofthe tab and periphery stack of the pouch of FIG. 4 taken along line10-10 in accordance with one embodiment of the invention. Cross-section1000 of periphery stack 420 and flap 430 can include the distinct layersof each of stack 420 and flap 430, as described above in connection withFIGS. 8 and 9. To ensure that the stack and flap are properlyintegrated, layer 1002 can be used simultaneously as both layer 912 ofperiphery stack 420 (FIG. 9) and layer 804 of flap 430 (FIG. 8).Adhesive layer 1010, which can correspond to adhesive layer 810 of flap430 (FIG. 8), can extend at least partially underneath periphery stack420 along with layer 820 of flap 430 (FIG. 8).

Device 500 can include several ports for interface with the electronicdevice. For example, device 500 can include one or more buttons or othercontrol means (e.g., a sliding mechanisms), connectors (e.g., USB or30-pin connectors, or a jack), speakers, sensors (e.g., proximity or IRsensors) or other interface elements that a user may need to accessthrough pouch 400. For example, pouch 400 can include connector opening452, button openings 452 and 454, wheel opening 456, and speakeropenings 458. Although the openings in pouch 400 were characterized, itwill be understood that these openings could be used for any otherinterface element, and that one opening could be used for severalinterface elements.

Opening 450 can be formed in any suitable element of the case. In theexample of FIG. 4, opening 450 has been made in flap 430. Opening 450can have any suitable size or use, including for example positioned andsized to let a connector pass through and engage a correspondinginterface of device 500. Opening 450 can be manufactured using anysuitable approach, including for example die cutting before or after theassembly of flap 430. Openings 452, 454 and 456 can have any suitablesize or use, including for example a position and size corresponding tobuttons or other interfaces for actuating device 500. Because openings452, 454, and 456 can be relatively large (e.g., large enough to allow auser's finger to pass), the portions of periphery stack 420 near oraround the openings can flare out when device 500 is inserted. Toprevent the flare out, periphery stack 420 or back layer stack 410(e.g., the stack having the openings) can include a stiffening layerthat maintains the integrity and shape of the opening. For example, thestacks can include a supplemental polycarbonate layer (e.g., apolycarbonate disk around the edges of the openings) and correspondingadhesive layers in the layer stack (e.g., an additional polycarbonatelayer instead of or adjacent to the rigid layer).

Openings 458 can include several holes through which audio waves canpropagate. To ensure optical audio propagation, openings 458 can besubstantially aligned with corresponding openings adjacent to a speakerof device 500. Openings 458 can have any suitable size, including forexample a larger number of small openings or a smaller number (e.g.,one) of larger openings. When smaller openings are used, periphery stack420 may be less prone to flaring out, as there is less material absentand therefore force is more evenly distributed. To ensure that the shapeof pouch 400 remains intact, periphery stack 420 can include anadditional layer of material (e.g., a softer material, such as anadditional layer of microfiber or polyurethane).

Back layer stack 410 can include a substantially continuous surface tobe placed in contact with a side of the device enclosure. For example, aside of the device opposite the display can be placed in contact withback layer stack 410. In some embodiments, back layer stack 410 canextend beyond the edges of periphery stack 420 and include some or allof a hinge and cover of the case. FIG. 11 is a schematic view of a basestack in accordance with one embodiment of the invention. Stack 1100 caninclude several distinct portions, including for example pouch portion1110, hinge portion 1120, and cover portion 1130 all within the samepiece of material. In particular, stack 1100 can be manufactured from atleast one layer of material sized to include the pouch, hinge and coverportions.

Stack 1100 can distinguish the different portions of the stack using anysuitable approach. In some embodiments, stack 1100 can include sectionsof harder material defining boundaries for the different portions. Forexample, stack 1100 can include hard element 1112 of pouch portion 1100,hard element 1122 of hinge portion 1120, and hard element 1132 of coverportion 1130. The hard elements can have any suitable size, includingfor example elements that extend almost or substantially to the sideboundaries of the stack. The space between the hard elements (e.g.,space 1115 and space 1125) can include softer material such that thedifferent hard elements can fold at least partially over each otheralong spaces 1115 and 1125. The hard elements can be constructed fromany suitable material including for example rigid layers (e.g.,polycarbonate layers) providing a that are flexible for bending aroundan axis in the plane of the layers, but stiff and resisting bendingaround an axis that is not in the plane of the layers (e.g.,perpendicular to the plane of the layers).

Each of pouch portion 1110, hinge portion 1120 and cover portion 1130can have any suitable size. For example, pouch portion 1100 can havesubstantially the same size as the periphery pouch (e.g., peripherypouch 420, FIG. 4). In particular, the size of pouch portion 1100 can beselected based on the expected size of an electronic device to be placedwithin the pouch (e.g., width 1130 corresponds to a dimension of thedevice). Hinge portion 1120 can have any suitable width 1131. Forexample, width 1131 can be selected to substantially match the thicknessof the device plus the thickness of the periphery stack, such that coverportion 1130 can fold over the device and lie directing on the devicedisplay. In particular, spaces 1115 and 1125 can be distributed toensure that cover portion 1130 can fold over the device and remain inplace over the device while protecting the entire device (e.g., thecover portion does not remain partially open, and the portion of coverportion 1130 adjacent to space 1125 is substantially in contact with thedevice).

Cover portion 1130 can have any suitable length 1132 and width 1134. Inparticular, length 1132 can be selected so that cover portion 1130 canat least cover a portion along the entire periphery of the peripherystack of the case (e.g., at least cover the ring of the peripherystack). Width 1134 can be selected such that it is less than or equal towidth 1133 of the pouch portion. In some embodiments, width 1134 can beselected to be less than width 1133, but at least enough to cover atleast a portion along the entire periphery of the periphery stack of thecase (e.g., at least cover the ring of the periphery stack). Width 1134can be distributed within width 1133 in any suitable manner, includingfor example off-centered (e.g., such that the distance between the eachside edge of the cover portion and the side edge of the correspondingpouch portion are different). In some embodiments, cover portion 1130can include a fastening mechanism for retaining the cover over theperiphery stack. The fastening mechanism can include, for example, amechanical snap, a magnetic snap, hook and fastener material, or anyother suitable fastening mechanism.

FIG. 12 is a cross-sectional view of base layer stack 1110 taken alongline 12-12 and connected to a peripheral layer stack in accordance withone embodiment of the invention. Cross-section 1200 of base layer stack1100 can include several layers constructed from different materials. Inparticular, base layer stack 1100 can include internal layer 1202 put incontact with the electronic device enclosure (e.g., electronic device500). To prevent damage to the device, layer 1202 can be constructedfrom a soft material. Such materials can include, for example, amicrofiber (e.g., polyester microfiber).

Layer 1202 can be coupled to rigid layer 1208 (e.g., a polycarbonatelayer) by adhesive layer 1204. In some embodiments, layer 1208 canextend through only portions of stack 1200 (e.g., the portions of thebase layer stack that include rigid elements). To ensure a proper bondbetween layer 1208 and the remaining layers, adhesive layers 1204, 1205and 1206 can be applied around layer 1208 (e.g., adhesive layers 1204and 1206 on the top and bottom surfaces of layer 1208, and layer 1205between layers 1202 and 1210 where there is no rigid layer 1208). Layers1204, 1205 and 1206 can be formed using any suitable adhesive, includingfor example a pressure or heat-sensitive adhesive (e.g., a polyurethanebased adhesive).

On its outermost surface, base layer stack 1200 can include externallayer 1212. Layer 1212 can include any suitable property, including forexample an aesthetically pleasing surface, a surface that is comfortableto the touch, resistant to stains, tears, or other damage, or has anyother property. In one implementation, layer 1212 can be constructedfrom polyurethane. Because polyurethane is stretchable, stack 1100 caninclude layer 1210 for resisting the deformation by stretching of layer1212. For example, layer 1210 can include a polyester knit that resiststo tension along the plane of the knit. Layer 1210 can be bonded tolayer 1212 using any suitable approach, including for example using anadhesive layer (not shown), but pressure, or any other suitableapproach. In some embodiments, an adhesive layer on the other side oflayer 1210 (e.g., adhesive layer 1206) can traverse layer 1210 (becauseit is knit) and ensure that layer 1210 bonds to layer 1212.

Stack 1200 can be assembled in any suitable manner. In some embodiments,each layer can be individually added and adhered or integrated in thestack in sequence. Alternatively, some or all of the layers can beoverlaid, and a pressure or heat-based process can be applied toassemble the stack. The individual layers can be pre-cut and assembled,or alternatively can be assembled and once the stack crated, cut to aparticular shape (e.g., die cut).

Base layer stack 1100 can be coupled to periphery stack 420 using anysuitable approach. In some embodiments, adhesive layer 1220 can beplaced between base layer stack 1100 and periphery stack 420 such thatthe edges of the stacks are connected. In some embodiments, individuallayers of each stack can be visible along the edge of the case (e.g.,knit layer 1210 and the corresponding knit layer of periphery stack 420can be visible). In some embodiments, or one or more layers of eachstack can stop before reaching the edge of the stack (e.g., similar tothe fiberglass and polycarbonate layers, described above). For example,layer 1202 and its counterpart in the periphery stack (e.g., microfiberlayers) can not extend to the edge of the stacks such that the adhesivelayers of each stack (e.g., adhesive layer 1205) can be used to couplebase layer stack 1100 to periphery stack 420.

In some embodiments, base layer stack 1100 can include tab 1150 coupledto the back surface of the stack (e.g., the surface opposite theperiphery stack, or the surface that is not placed in contact with thedevice). Tab 1150 can be positioned at any suitable distance from edgesof base layer stack 1100. For example, tab 1150 can be equidistant fromthe side edges of base layer stack 1100 (e.g., the sides that includethe sides of cover portion 1130), such that distances 1160 and 1162 arethe same. In some embodiments, distances 1160 and 1162 can be different,for example based on characteristics of pouch portion 1110 or cover 1130(e.g., the placement of rigid elements, openings in the cover or pouch,or other physical attributes of the stack). Although only one tab 1150is shown in FIG. 11, base layer stack 1100 can include several tabsdistributed along the stack (e.g., distributed based on correspondingelements of the cover portion).

Tab 1150 can be positioned at any suitable distance from bottom edge1112 of pouch portion 1110. In particular, distance 1164 can beselected, along with width 1131 and length 1132 such that cover portion1130 can be folded back over pouch portion 1110 and the edge of thecover portion inserted into tab 1150. This can form a triangular prismthat a user can place on hinge portion 1120 or on pouch portion 1130.FIGS. 13A and 13B are end views of a folded over case defining a prismin accordance with one embodiment of the invention. Case 1300 caninclude pouch portion 1310, hinge portion 1320, and cover portion 1330.Cover portion 1330 can be folded over pouch portion 1310 such that coverportion 1330 can be engaged in tab 1350. Case 1300 can then define aprism-type shape by which the internal surface of pouch portion 1310(e.g., the surface of pouch portion 1310 through which a deviceinterface can be accessed) is exposed on an outer surface of the prism.

Tab 1350 can be placed on the back surface of pouch portion 1310 at anysuitable position, including for example a position such that the prismdefines angle 1352 between pouch portion 1310 and cover portion 1330,and angle 1354 between pouch portion 1310 and hinge portion 1320. Eachangle 1352 and 1354 can be selected based on any criteria, including forexample desired angles for performing particular operations with thedevice. In one implementation, angle 1352 can be selected such that auser can easily type on an interface of the device. In anotherimplementation, angle 1354 can be selected so that the user can viewcontent (e.g., media) displayed by the device.

Returning to FIG. 11, tab 1150 can be constructed using any suitableapproach. In some embodiments, tab 1150 can be a component added to thesurface of base layer stack 1100. Tab 1150 can include periphery 1152defining the structure of tab 1150 and enclosing an area of the tab. Tabelement 1154 can extend from a side of periphery 1152 such that thecover can engage tab element 1154. Tab element 1154 can be offset fromthe surface of base layer plate 1100 by gap 1156, which can extendwithin the area defined by periphery 1152. FIG. 14 is a cross-sectionalview of tab 1150 taken along line 14-14 in accordance with oneembodiment of the invention. Cross-section 1400 of tab 1150 can includeseveral layers constructed from different materials. In particular,cross-section 1400 can include softer materials to be placed in contactwith the cover, and harder materials to ensure that the tab can retainthe cover. In particular, tab 1150 can include outermost layer 1402.Layer 1402 can include any suitable property, including for example anaesthetically pleasing surface, a surface that is comfortable to thetouch, resistant to stains, tears, or other damage, or has any otherproperty. In one implementation, layer 1402 can be constructed frompolyurethane. Because polyurethane is stretchable, tab 1150 can includelayer 1404 for resisting the deformation by stretching of layer 1402.For example, layer 1404 can include a polyester knit that resists totension along the plane of the knit. Layer 1404 can be bonded to layer1402 using any suitable approach, including for example using anadhesive layer (not shown), but pressure, or any other suitableapproach. In some embodiments, an adhesive layer on the other side oflayer 1404 (e.g., adhesive layer 1406 or 1407) can traverse layer 1404(because it is knit) and ensure that layer 1404 bonds to layer 1402.

To provide stiffness to tab 1150 so that the tab can retain the coverwhen it is inserted in the tab, tab 1150 can include rigid layer 1410(e.g., a polycarbonate layer) coupled to the other layers by adhesivelayer 1406. In some embodiments, layer 1410 can extend through onlyportions of tab 1150 (e.g., the portions of the tab that include rigidelements, such as tab element 1154 and periphery 1152). To ensure aproper bond between layer 1410 and the remaining layers, adhesive layers1406, 1407 and 1408 can be applied around layer 1410 (e.g., adhesivelayers 1407 and 1408 on the top and bottom surfaces of layer 1410, andlayer 1406 between layers 1404 and 1412 where there is no rigid layer1410). Layers 1406, 1407 and 1408 can be formed using any suitableadhesive, including for example a pressure or heat-sensitive adhesive(e.g., a polyurethane based adhesive).

Tab 1150 can include internal layer 1412 that the cover can contact whenit is folded into tab 1150. To prevent damage to the cover, layer 1412can be constructed from a soft material. Such materials can include, forexample, a microfiber (e.g., polyester microfiber). Tab 1150 can thencoupled to pouch portion 1320 using adhesive layer 1414.

Tab 1150 can be assembled in any suitable manner. In some embodiments,each layer can be individually added and adhered or integrated in thestack in sequence. Alternatively, some or all of the layers can beoverlaid, and a pressure or heat-based process can be applied toassemble the stack. The individual layers can be pre-cut and assembled,or alternatively can be assembled and once the stack crated, cut to aparticular shape (e.g., die cut).

FIG. 15 is a flowchart of an illustrative process for assembling a casefor protecting an electronic device in accordance with one embodiment ofthe invention. Process 1500 can begin at step 1502. At step 1504, theindividual layers forming each stack of the case can be aligned. Forexample, each layer can be cut and aligned relative to the other layers.As another example, sheets of material can be overlaid with layers thatdo not extend through the entire stack (e.g., rigid layers such aspolycarbonate layers or fiberglass layers). At step 1506, the alignedlayers can be assembled into stacks. The layers can be assembled usingany suitable approach, including for example using heat and/orpressure-based processes or adhesive. In some embodiments, one or morecuts can be applied to the assembled stacks to provide openings forinterfaces of a device to be placed in the case.

At step 1508, the assembled stacks can be connected to form a case. Forexample, one or more layers of adhesive can be placed between the stacksto secure the stacks. As another example, a heat or pressure basedprocess can be used to connect the assembled stacks. At step 1510, thetab can be connected to the case (e.g., to the back of the base layerstack), and various cuts or other finishing processes can be performed.For example, the tab can be assembled to the stack via an adhesive, andthe cuts in the flap or other portions of the periphery stack can beperformed to allow access to device interface elements. In someembodiments, the external surfaces of the case can be finished (e.g.,provide a stain resistance coating). In some embodiments, the edges ofthe case can be refined if necessary. Process 1500 can then end at step1512.

The previously described embodiments are presented for purposes ofillustration and not of limitation. It is understood that one or morefeatures of an embodiment can be combined with one or more features ofanother embodiment to provide systems and/or methods without deviatingfrom the spirit and scope of the invention. The present invention islimited only by the claims which follow.

What is claimed is:
 1. A protective case for a portable electronicdevice, the protective case comprising: a pouch element configured tocarry the portable electronic device, the pouch element comprising: afirst end defining an opening through which the portable electronicdevice is inserted into the pouch element, a second end opposite thefirst end, and a back layer positioned between the first end and thesecond end; and a flap coupled to the pouch element at the first end,the flap comprising: a first element, and a second element positionedbetween the first element and the pouch element, the second elementrotationally coupled to the pouch element and the first element,wherein: in a closed configuration, the first element is folded into theopening of the pouch element in a first support configuration, the firstelement and the second element support the back layer such that thepouch element is inclined at a first angle, and in a second supportconfiguration, the first element and the second element support the backlayer such that the pouch element is inclined at a second angle that isdifferent from the first angle.
 2. The protective case as recited inclaim 1, wherein the back layer that defines a continuous surface. 3.The protective case as recited in claim 1, wherein the second element isconfigured to cooperate with the pouch element to retain the portableelectronic device in the closed configuration.
 4. The protective case asrecited in claim 1, wherein the pouch element includes an external layercomprising polyurethane, a polyester knit layer adjacent the externallayer, and a rigid layer bonded to the polyester knit layer by anadhesive and comprising fiberglass or polycarbonate.
 5. The protectivecase as recited in claim 1, further comprising a cover, wherein the flapis separate from the cover.
 6. A protective case for a portableelectronic device, the protective case comprising: a pouch elementconfigured to receive the portable electronic device, the pouch elementbeing characterized as having a first edge and a second edge oppositethe first edge, the pouch element defining an opening that is closer tothe first edge than the second edge, the pouch element comprising: anexternal layer comprising polyurethane, a polyester knit layer adjacentthe external layer, and a rigid layer bonded to the polyester knit layerby an adhesive, the rigid layer comprising fiberglass or polycarbonate;a cover connected to the pouch element at the first edge, wherein thecover is configured to provide multiple support structures for the pouchelement; and a flap separate from the cover and connected to the pouchelement at the first edge, wherein a closed configuration comprises theflap inserted into the opening and covering the electronic device whenthe electronic device is in the pouch element.
 7. The protective case asrecited in claim 6, wherein the flap comprises one or more rigidelements.
 8. The protective case as recited in claim 6, wherein thecover is a flexible and includes a microfiber material.
 9. Theprotective case as recited in claim 6, wherein the pouch element furthercomprises a second opening that allows for user interface with a displayof the portable electronic device when the portable electronic device ispositioned in the pouch element.
 10. The protective case as recited inclaim 6, wherein: in a first support configuration, the cover supportsthe pouch element at a first angle, and in a second supportconfiguration, the cover supports the pouch element at a second anglethat is different from the first angle.
 11. A protective case for aportable electronic device, the protective case comprising: a pouchelement comprising a first end and a second end opposite the first end,the pouch element defining an opening configured to receive the portableelectronic device; and a foldable flap comprising a first element and asecond element positioned between the first element and the pouchelement, the second element rotationally coupled to the pouch element atthe first end, wherein: in a first closed configuration, the foldableflap covers a display of the portable electronic device, in a secondclosed configuration, the first element is positioned in the opening,and in a support configuration, the foldable flap is folded behind thepouch element and forms a triangular support for the pouch element. 12.The protective case as recited in claim 11, wherein the triangularsupport is capable of including the pouch element at a first angle andat a second angle, the first angle being different than the secondangle.
 13. The protective case as recited in claim 11, wherein the firstelement comprises a fastening mechanism for retaining the first elementover the pouch element in the support configuration.
 14. The protectivecase as recited in claim 13, wherein the fastening mechanism comprises amechanical snap, a magnet, or a hook and fastener material.
 15. Theprotective case as recited in claim 11, wherein the first element islarger than the second element.
 16. The protective case as recited inclaim 11, wherein the pouch element includes an external layercomprising polyurethane, a polyester knit layer adjacent the externallayer, and a rigid layer bonded to the polyester knit layer by anadhesive and comprising fiberglass or polycarbonate.
 17. The protectivecase as recited in claim 11, wherein the pouch element comprises: astack comprising one or more layers of material.
 18. The protective caseas recited in claim 17, wherein the opening comprises a size and shapeto receive the flap.